Staco Energy FirstLine P User manual

003-2460 Rev C
FirstLine P
FirstLine P 924
160-250kVA UPS
USER MANUAL

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No reproduction of any part of this manual, even partial, is permitted without the authorization of Staco
Energy Products Company. The Staco Energy Products Company reserves the right to modify the
product described herein, in order to improve it, at any time and without notice.
301 Gaddis Boulevard • Dayton, Ohio 45403
U.S. Toll Free 866-261-1191
[phone] • Fax: [phone]
Web site: www.stacoenergy.com
Thank you for choosing our product.
Staco Energy is highly specialized in the development and production of uninterruptible power
systems (UPS). The UPS’s of this series are high quality products, carefully designed and
manufactured to ensure optimum performance.

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Applicability
This manual applies to the following models:
FLU-160-xx
160 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta
FLU-200-xx
200 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta
FLU-250-xx
250 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta
The wye output configuration that provides an output neutral connection is only permitted
when an input neutral is provided; delta-wye configuration is prohibited.
The source must have a grounded neutral, even if the neutral is not connected to the UPS; a
delta source may not be ungrounded or corner grounded.
Please refer to Section C.3 Mains and Load Connections. for additional information.
Safety Warnings
IMPORTANT SAFETY INSTRUCTIONS - SAVE THESE INSTRUCTIONS
This manual contains important instructions for Models 65, 80, 100 and 125kVA FIRSTLINE P series
UPS that should be followed during installation and maintenance of the UPS. Please read all instructions
before operating the UPS and save this manual for future reference.
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
a. Do not use outdoors.
b. Do not route wiring across or near hot surfaces.
c. Do not install near gas or electric heaters.
d. Use caution when servicing batteries. Battery acid can cause burns to skin and eyes. If acid is
spilled on skin or in eyes, flush acid with fresh water and contact a physician immediately.
e. Unit should be installed where it will not readily be subjected to tampering by unauthorized
personnel.
f. The use of accessory equipment not recommended by the manufacturer may cause an unsafe
condition.
g. Do not use this UPS for other than intended use.
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE
PARTS inside the UPS.
WARNING
DANGER

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To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity
controlled, indoor environment, free of conductive contaminants. Do not operate near water
or excessive humidity (95% maximum).
Input and output over-current protection and disconnect switches must be provided by
others.
High ground leakage current may be present. Do not operate the unit without a proper
protective ground.
WARNING
Batteries can present a risk of electrical shock or burn from high short circuit current.
Observe proper precautions. Servicing should be performed by qualified service personnel
knowledgeable of batteries and required precautions. Keep unauthorized personnel away
from batteries.
There is a risk of explosion if batteries are replaced by an incorrect type. Replace with same
type and rating only.
Proper disposal of batteries is required. Refer to your local codes for disposal requirements.
Never dispose of batteries in a fire
Emergency Interventions
The following information is of a general nature.
First aid interventions
Company regulations and traditional procedures should be followed for any first aid intervention that may
be required.
Firefighting measures
1. Do not use water to put out a fire, but only fire extinguishers that are suitable for use with
electrical and electronic equipment.
2. If exposed to heat or fire, some products may release toxic fumes into the atmosphere. Always
use a respirator when extinguishing a fire.
WARNING
WARNING

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Symbols used in the Manual
In this manual, some operations are shown by graphic symbols to alert the reader to the dangerous
nature of the operations:
Danger / Risk of Electric Shock
This symbol indicates possibility of serious injury
or substantial damage to the unit, unless
adequate precautions are taken.
Warning
This symbol indicates important information which
must be understood and any stated precautions
taken
Note
Protective Equipment
No maintenance operations shall be carried out on the unit without wearing the Personal Protective
Equipment (PPE) described below. Personnel involved in the installation or maintenance of the unit must
be properly clothed.
The following signs show the protective equipment that should be worn. The various items of PPE must
be selected and sized according to the nature of the hazard (particularly electrical) posed by the unit.
Accident
prevention
footwear
Protective eyewear
Protective
clothing
Helmet
Work gloves
General Precautions
This manual contains detailed instructions for the use, installation and start-up of the UPS. Read the
manual carefully before installation. For information on using the UPS, the manual should be kept close
at hand and consulted before carrying out any operation on the UPS.
This UPS has been designed and manufactured in accordance with the standards for the product, for
normal use and for all uses that may reasonably be expected. It may under no circumstances be used for
any purposes other than those envisaged, or in any other ways than those described in this manual. Any
interventions should be carried out in accordance with the criteria and the time-frames described in this
manual.

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Table of Contents
Applicability..............................................................................................................................................iii
Safety Warnings ......................................................................................................................................iii
Emergency Interventions .........................................................................................................................iv
First aid interventions ...........................................................................................................................iv
Firefighting measures...........................................................................................................................iv
Symbols used in the Manual.....................................................................................................................v
Protective Equipment................................................................................................................................v
General Precautions.................................................................................................................................v
1. Layout..................................................................................................................................................1
1.1 Views..............................................................................................................................................1
1.2 Preliminary Operations...................................................................................................................3
1.2.1 Removing the Packaging and Positioning the Device .............................................................. 3
1.2.2 Storage....................................................................................................................................3
1.2.3 Handling ..................................................................................................................................3
1.2.4 Cooling of the Premises...........................................................................................................4
2. Installation............................................................................................................................................5
2.1 Accessing the UPS terminals .........................................................................................................5
2.2 UPS - Single Module Configuration ................................................................................................ 6
2.3 Cable Entry.....................................................................................................................................7
2.4 Connect of Power Cables...............................................................................................................9
2.4.1 Input Line without Neutral ........................................................................................................ 9
2.4.2 Single Input............................................................................................................................ 10
2.4.3 Connection of Power Cables for Dual input Unit..................................................................... 12
2.5 Differential (GFI)........................................................................................................................... 14
2.6 Emergency Power off Device (EPO)............................................................................................. 14
2.7 Connection of Signals and Remote Commands ........................................................................... 15
2.7.1 Remote Commands, Alarms and EPO................................................................................... 17
2.7.2 RS232-1 and RS232-2........................................................................................................... 18
2.7.3 SLOT 1 and SLOT 2.............................................................................................................. 19
2.7.4 Optional Remote Alarm Cards ............................................................................................... 19
2.7.5 Optional MODEM................................................................................................................... 20
2.7.6 Optional MULTI I / O.............................................................................................................. 20
2.7.7 Optional Battery Temperature Sensor.................................................................................... 20
2.7.9 Multi Panel............................................................................................................................. 20
2.7.10 SWOUT and SWMB aux...................................................................................................... 21
3. Operation...........................................................................................................................................23
3.1 Start up......................................................................................................................................... 24
3.1.1 Before Start Up...................................................................................................................... 24
3.1.2 Start-Up Procedure Single Module......................................................................................... 24
3.2 Single UPS and Load Shutdown................................................................................................... 25
3.3 Transfer to Bypass/Inverter .......................................................................................................... 25
3.4 Operating Modes.......................................................................................................................... 25
3.4.1 On-line Factory Setting .......................................................................................................... 25

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3.4.2 Standby-On / Smart Active..................................................................................................... 25
3.4.3 Standby-Off (with Mains Present the Load is not Powered) ................................................... 26
3.4.4 Stabilizer (Operation In On-Line Mode Without Battery)......................................................... 26
4. Control Panel and Display.................................................................................................................. 27
4.1 Signal panel functions .................................................................................................................. 27
4.2 Graphic Display............................................................................................................................ 29
4.2.1 Diagram Items Shapes........................................................................................................... 30
4.2.2 Keys Numbers and Icons....................................................................................................... 30
4.3 Basic menu (text lines area) ......................................................................................................... 31
4.3.1 The First Line of the Basic Menu............................................................................................ 31
4.3.2 The Second Line of the Basic Menu....................................................................................... 32
4.4 Language setting menu (keys 1, 1)............................................................................................... 33
4.5 Measurements menus (key 2) ...................................................................................................... 34
4.6 Full page Measurements and output waveforms (key 2, 7)........................................................... 36
4.7 Controls Menu (key 3) .................................................................................................................. 37
4.7.1 Battery Test (Keys 3, 2) ......................................................................................................... 37
4.7.2 Customizing........................................................................................................................... 38
4.7.3 "Recorder": Recorded Events (key 4)..................................................................................... 48
4.7.4 Disabling the Audible Alarm (key 5) ....................................................................................... 50
4.7.5"Clock": Date/Time (key 6)...................................................................................................... 51
4.7.6 "Arrow Down": Internal Codes, Firmware Ver.(key 7)............................................................. 51
5. UL924 Emergency Lighting Systems............................................................................................... 52
6. Maintenance......................................................................................................................................53
6.1 Periodic Maintenance (to be carried out by trained personnel and with doors closed).................. 53
6.2 Maintenance Inside the UPS (factory authorized personnel only)................................................. 53
6.3 Ordinary Maintenance for Batteries (trained personnel only) ........................................................ 53
6.4 Recommended Replacement Intervals......................................................................................... 54
7. Specifications..................................................................................................................................... 55
7.1 Electrical Specifications................................................................................................................ 55
7.2 Environmental Requirements ....................................................................................................... 56
7.3 Mechanical Specifications ............................................................................................................ 56
7.4 Rated Currents............................................................................................................................. 57
7.4.1 Input (Single Input Module).................................................................................................... 57
7.4.2 Rectifier Input (Dual Input Module)......................................................................................... 57
7.4.3 Bypass Input (Dual Input Module).......................................................................................... 57
7.4.4 Output.................................................................................................................................... 57
7.4.5 Battery................................................................................................................................... 57
7.5 Torque specifications.................................................................................................................... 58
Appendix A – Alarms ............................................................................................................................. 59
Appendix B - Optional remote commands.............................................................................................. 62
Appendix C - Parallel Configuration....................................................................................................... 63
C.1 Introduction..................................................................................................................................63
C.2 Electrical System Set-Up ............................................................................................................. 64
C.2.1 Input...................................................................................................................................... 64

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C.2.2 Ground Fault......................................................................................................................... 64
C.2.3 Emergency Power Off Device (EPO)..................................................................................... 64
C.2.4 External Maintenance Bypass............................................................................................... 65
C.3 Mains and Load Connections....................................................................................................... 65
C.4 Installing Parallel kit..................................................................................................................... 66
C.4.1 Parallel Card Installation........................................................................................................ 67
C.4.2 Parallel Card Connections..................................................................................................... 68
C.4.3 Parallel Card RJ45 Installation .............................................................................................. 68
C.4.4 Parallel Card RJ45 Connections............................................................................................ 69
C.5 Connection of Signals.................................................................................................................. 69
C.5.1 RJ45-flat-adapter signals parallel card. ................................................................................. 70
C.5.2 Single UPS Configured in Parallel......................................................................................... 70
C.5.3 Two UPS’s in Parallel............................................................................................................ 71
C.5.4 Three UPS’s in Parallel ......................................................................................................... 71
C.6 Parallel Start-up procedure .......................................................................................................... 72
C.7 Parallel Communication Troubleshooting..................................................................................... 73
C.7.1 Normal Condition................................................................................................................... 73
C.7.2 Single Opened Parallel Cable................................................................................................ 73
C.7.3 Multiple Opened Parallel Cable............................................................................................. 74
C.8 Mechanical Bypass...................................................................................................................... 74
C.8.1 Mechanical bypass on a single unit....................................................................................... 74
C.8.2 Mechanical bypass on the whole system............................................................................... 75
C.9 Insertion and removal with UPS’s operating (hot swap)............................................................... 76
C.9.1 Example of Hot Insertion....................................................................................................... 76
C.9.2 Example of Hot Removal....................................................................................................... 77

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Figures
Figure 1 - FLU cabinet front view.............................................................................................................1
Figure 2 - FLU-T cabinet front view..........................................................................................................2
Figure 3 – Single Input 1-Line ................................................................................................................. 6
Figure 4 - Dual Input 1-Line.....................................................................................................................6
Figure 5 – FLU bottom Cable Entry Layout.............................................................................................. 7
Figure 6 – FLU-T bottom Cable Entry Layout .......................................................................................... 8
Figure 7 - Schematic diagram: Single Input without Source Neutral......................................................... 9
Figure 8 - Schematic diagram: Dual Input without Source Neutral............................................................ 9
Figure 9 – FLU UPS Single Input Power Connection Terminals............................................................. 10
Figure 10 – FLU-T UPS Single Input Power Connection Terminals ....................................................... 11
Figure 11 – FLU UPS Dual Input Power Connection Terminals............................................................. 12
Figure 12 – FLU-T UPS Dual Input Power Connection Terminals.......................................................... 13
Figure 13 – Emergency Power Off (EPO) ............................................................................................. 14
Figure 14 – FLU Signals and Remote Command Connections .............................................................. 15
Figure 15 – FLU-T Signals and Remote Command Connections........................................................... 16
Figure 16 – Remote Alarm Contacts......................................................................................................18
Figure 17 – RS232-2 Female Connection ............................................................................................. 18
Figure 18 – RS232-1 Male Connection ................................................................................................. 19
Figure 19 – Single Module Wrap-around bypass................................................................................... 21
Figure 20 – Parallel System Wrap-around bypass................................................................................. 22
Figure 21 – Single Input 1-Line.............................................................................................................. 23
Figure 22 – Dual Input 1-Line................................................................................................................ 23
Figure 23 – Signal Panel....................................................................................................................... 27
Figure 24 – Graphic Display.................................................................................................................. 29
Figure 25 – Typical (3) Module Parallel System .................................................................................... 63
Figure 26 – Recommended Ground Fault Interrupter Layout ................................................................ 64
Figure 27 – Parallel System EPO.......................................................................................................... 64
Figure 28 - Three units connected in parallel (Typical).......................................................................... 65
Figure 29 – Parallel Card Installation..................................................................................................... 67
Figure 30 – Parallel Card connections................................................................................................... 68
Figure 31 – Parallel Card RJ45 Installation ........................................................................................... 68
Figure 32 – Parallel Card Flat Cable Installation.................................................................................... 69
Figure 33 - Parallel Control Routing ...................................................................................................... 69
Figure 34 - RJ45-flat-adapter signals parallel card................................................................................ 70
Figure 35 – Parallel Connection – Single Module.................................................................................. 70
Figure 36 – Parallel Connection – Two Modules ................................................................................... 71
Figure 37 – Parallel Connection – Three Modules................................................................................. 72
Tables
Table 1 - Torque Specifications for Terminal Blocks on Customer Interface Board................................. 16
Table 2 - Interface Remote Command Alarms and EPO ........................................................................ 17
Table 3 - Interface Terminal Connector ................................................................................................. 22
Table 4 - Led Status Indicators.............................................................................................................. 28
Table 5 - Diagram Items Shapes........................................................................................................... 30
Table 6 - Keys Numbers and Icons........................................................................................................ 30
Table 7 – Battery Models approved for UL924....................................................................................... 52
Table 8 – UL924 Approved Systems...................................................................................................... 52
Table 9 - Recommended Replacement Intervals................................................................................... 54
Table 10 – Parallel Kit Components ...................................................................................................... 66

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1. Layout
1.1 Views
Figure 1- FLU cabinet front view
A - Control Panel with Graphic Display
B - Door Handle
C - Ventilation Grilles
D - Communication Area
E - Front Cover Panel with Ventilation Grilles
F - Switch Cover Panel
G - Door
1 - SWIN: Input Power Switch
2- SWBY: Static Switch Bypass Input
3 - SOUT: Static Switch Output

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Figure 2- FLU-T cabinet front view
A - Control Panel with Graphic Display
B - Door Handle
C - Ventilation Grilles
D - Communication Area
E - Front Cover Panel with Ventilation Grilles
F - Switch Cover Panel
G - Door
1 - SWIN: Input Power Switch
2 - SWBY: Static Switch Bypass Input
3 - SOUT: Static Switch Output
4 - SWMB: Mechanical Bypass Switch

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1.2 Preliminary Operations
1.2.1 Removing the Packaging and Positioning the Device
On delivery, the packaging must be inspected to ensure that it is whole and that it has not been crushed
or dented. Check in particular that neither of the two impact resistant devices on the packaging is red; if
one of them is red; follow the instructions on the packaging.
The essential details of the device are provided on the shipping document. The marking, weight and
dimensions of the various items making up the packing list are shown.
Check the state of the device by means of a visual inspection of both the inside and the outside. Any
dents seen mean that it has suffered shocks during shipping, which could compromise the normal
operation of the device.
1.2.2 Storage
Place the device in covered premises that are protected from direct contact with atmospheric agents and
dust. The following environmental values are those allowed in the storage area:
Temperature: -13°F to +167°F (-25 to + 75 °C)
Relative humidity: 30-95 % max.
WARNING
For the installation of a battery cabinet, if provided with the uninterruptible power supply, follow
the instructions given in the specific manual.
The list of material provided may vary depending on the order specifications. Most systems include the
following: this manual, the installation drawing, the warranty and eventual accessories.
1.2.3 Handling
The equipment must only be handled by adequately trained personnel.
1 Insert the forks of the fork-lift truck in the lower part of the device, from the front or back, and
ensure that they stick out about 12 inches on the other side.
2 Secure the device to the fork-lift before moving it.
In order to avoid the risk of the device overturning, ensure that it is firmly secured to the
fork-lift truck by means of appropriate ropes before moving it.
When being moved the cabinet should be handled with care; shocks or drops can damage it. Once in
position, remove the packaging carefully in order not to scratch the device.
The packaging should be removed as follows:
1. Cut the bands
2. Slide away the carton from above.
3. Remove the screws securing the cabinet to the wooden base.
DANGER

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1.2.4 Cooling of the Premises
The recommended operating temperature for the lifetime of the UPS
and of the batteries is between 20 and 25°C. The lifespan of the
battery depends on the operating temperature; with an operating
temperature increase from 20°C to 30°C, the lifespan of the
batteries is halved.
The airflow inside UPS is by the fans located inside the UPS (forced
convection) and by the air around the side panels (natural
convection).
In order to ensure proper air circulation measures must be taken
during installation to avoid any obstructions to the free circulation of
air. These include the following:
•Ensure a distance of at least 24 inches from the ceiling, so as
not to hinder air extraction,
•Leave a free space of at least 36 inches at the front of the
equipment to ensure both the circulation of the air and
installation and maintenance operations;
•With natural convection the thermal load is dissipated to the
outside through the walls; thus a cabinet placed against a wall or in a hollow dissipates less heat than
one located in a free environment.
The following rule must be observed:
Leave at least one of the three side walls free: right, left or back.
•The bottom side kick panels must not be mounted for installations where cabinets are placed side by
side.

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2. Installation
•Check the Safety Instructions.
•Any incorrect connection or handling may cause damage to the UPS and/or the loads
connected to it. Read these instructions carefully and follow the steps indicated.
•This UPS must be installed by qualified electrician.
•It is advisable to provide a maintenance bypass switch or an electrical panel with individual
protection for input, output, and static bypass, as well as a manual bypass. This allows isolation
of unit during preventive maintenance or repair.
2.1 Accessing the UPS terminals
The following operations must be performed while the UPS is disconnected from the utility
mains power, switched off and all the input and output power switches on the equipment are
open. Before performing connection, open all the input and output power switches and
check that the UPS is completely isolated from all power sources: battery and AC power
line. In particular, check that:
- UPS input line is completely isolated;
- Battery circuit breaker/disconnect is open;
- All UPS power and load connection switches (SWIN, SWBY, SWOUT and SWMB) are
in the open position;
- No dangerous voltages are present (use a multimeter).
The first connection to be performed is the protective wire (earth ground cable) which has to
be inserted into the terminal labeled PE. The UPS must operate with the grounding system
connected.
WARNING
•Do not connect the output neutral to the input neutral.
•If the input connection is Delta the UPS can supply only Delta load.
•The output neutral must not be connected unless the UPS is the Wye version supplied
with an input neutral.
•TRANSFORMER BOXES (optional) are available for converting the distribution
systems from 3 to 4 wires.
•If a three-phase non-linear load is connected to the output, the current on the neutral
conductor can reach a value equal to 1.5 times the value of the phase current.
Dimension the input/output neutral cable appropriately taking this fact into account.
•The UPS cannot feed from a corner ground or mid-point grounded delta supply
source.
•Use only lugs or cables with tin-plated eyes for the connections.
•Ensure correct phase rotation at the input and output terminals
•Ensure correct polarity battery connections
The DC input requires a disconnect means which is provided in most Staco supplied battery
cabinets.
AC and DC cables and cable lugs are to be provided by others as part of the UPS installation
DANGER

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Each model can be configured for a delta input source with a delta connected load or for a wye
input with a wye connected load. If the load requires a neutral connection (i.e. wye), then an
input neutral must be provided. Refer to the Power Connection terminals diagrams later in this
section for details concerning configuration of the neutral to ground bond.
2.2 UPS - Single Module Configuration
The UPS is designed to work as Single input Unit or as Dual input Unit.
Figure 3– Single Input 1-Line
Figure 4- Dual Input 1-Line

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2.3 Cable Entry
The cables can enter in the UPS from the bottom or from the top with the optional (Top Entry Cabinet)
Proceed as follows in order to open the UPS
1. Open the door
2. Remove the switch cover panel
3. Remove the bottom cable entry cover plates
4. Drill or punch conduit holes in the cover plates
5. Route the power cable through the bottom to the UPS terminals in base to your configuration
(see Figure 5and Figure 6)
Figure 5 – FLU bottom Cable Entry Layout

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Figure 6 – FLU-T bottom Cable Entry Layout

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2.4 Connect of Power Cables
2.4.1 Input Line without Neutral
If utility is a 3-wire source and the load requires a neutral, a transformer must be inserted either on the
mains supply line or on the bypass line.
Figure 7- Schematic diagram: Single Input without Source Neutral
Figure 8- Schematic diagram: Dual Input without Source Neutral

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2.4.2 Single Input
Connect the input, output and battery cables to the terminals as shown in Figure 9 and Figure 10:
Figure 9– FLU UPS Single Input Power Connection Terminals
For the Input, Output and Battery connections, follow the order from the top to bottom, or
right to left, as described in the boxes. The label marked “N” present on the terminal
identifies the neutral terminal.
The single input is a factory default configuration. Do not remove the bypass jumper. The input phase
connections are made using bolts to one of the three holes in the busbar. Do not loosen the bolts that
attach the busbar.
The UPS is provided with a separate busbar that connects the Neutral Output to the frame
Ground for delta input connection. This is required to meet NEC grounding code for separately
derived neutrals. When a Neutral is provided in a Wye configured input connection the busbar
must be removed.
Once installation has been completed inside the equipment, put the switch cover panel back and close
the door.